Heater and Heating System

ABSTRACT

A heater and heating system for installation adjacent a valve to control temperature near the valve is disclosed. In an example, the heating system includes a housing having a heating chamber formed therein, the heating chamber configured to retain a heating fluid. The heating system also includes an electric heating element disposed in thermal contact with the heating chamber. The heating system also includes a connection to attach the heating chamber to the valve.

PRIORITY CLAIM

This application claims the benefit of U.S. Provisional Patent Application. No. 61/908,445 filed Nov. 25, 2013 and titled “Valve Heater” of Troy A. Green, hereby incorporated by reference for all that is disclosed as though fully set forth herein.

BACKGROUND

Tanks are used in the oil and gas industry to store volumes, often in cold and even extreme cold environments. It is important that the tank contents do not freeze. While tank heaters can be used to reduce freezing, this alone is often insufficient. For example, valves and pipelines associated with the tanks may still freeze.

When valves freeze, an open-flame torch is typically applied to the exterior of the valve to heat and thaw the valve. However, an open flame can cause an undesirable and dangerous ignition (e.g., oils or other combustibles) even if only small residues are present on the valve exterior and/or nearby. Other approaches to reduce the occurrence of valves freezing is to wrap the valves with heat tape, or simply leave the valves open. But each of these approaches has yet further disadvantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of an example valve heater installed between a valve and a section of conduit.

FIGS. 1A-1B are perspective views of an example valve heater.

FIG. 2 is a side plan view of the example valve heater shown in FIGS. 1A-1B.

FIG. 3 is a cross-sectional view of the example valve heater shown taken along lines 3-3 in FIG. 1B.

FIG. 4 illustrates a connection on the example valve heater with a control box (see FIG. 5) shown removed.

FIG. 5 illustrates a control box for the example valve heater.

FIG. 6 shows another example valve heater.

FIGS. 7A-B illustrate the example valve heater shown in FIG. 6 as the valve heater may be implemented on a railroad tanker car.

DETAILED DESCRIPTION

Example valve heaters are disclosed herein as these may be used to enable operation of valves (e.g., a four-inch butterfly style valve) when freezing temperatures may otherwise prevent the valves from opening and closing. In an example, the valve heater may maintain a raised temperature of the fluid in and/or near the valve to maintain proper operation of the valve.

In an example, the valve, heater may be implemented for valves commonly found in the oil and gas industry, although the valve heater is not limited to any particular end-use, For example, another valve heater is disclosed herein which may be implemented for a railroad tanker car.

It is noted that other applications of the valve heater may include, but are not limited to, use with any valve (e.g., a valve using a flange style application) of any configuration and/or dimension which may be provided in cold weather environments, such as frac tanks, water manifolds, and mud pumps.

Indeed, the valve heater is not limited to use in cold weather environments. For example, the valve heater may also find application with asphalt valves in hot plants, wherein any cooling below the high temperatures needed to fluidize asphalt may result in the valve becoming inoperable. As such, the valve heater may be used to maintain the high temperatures needed to prevent the asphalt from cooling such that it would cause the valve to stick or otherwise become inoperable.

As such, the valve heater reduces or altogether eliminates the need for open-flame torches and/or the need to leave the valves open (potentially releasing hazardous fluids). In an example, a total rebuild of electrical components, including wiring can be performed without having to remove the valve heater.

Before continuing, it is noted that as used herein, the terms “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”

FIG. 1 is an illustration of an example valve heater 10. In an example, the valve heater 10 may be implemented as an inline heating system. That is, the heating system may be installed adjacent a valve 1 and a section of conduit 2. For example, the valve heater 10 may include a connection to attach the heating chamber to the valve 10. In an example, the connection is a first flange 12 to connect the valve heater 10 to the valve 1. The connection may also include a second flange 14 to connect to connect to the section of conduit 2.

The valve heater 10 is configured to maintain fluid (or other matter) in conduit 2 near the valve 1 at a predetermined temperature. For example, the temperature can be selected to be above freezing so that the fluid (or other matter) in the conduit 2 immediately adjacent the valve 1 does not freeze and render the valve inoperable.

The temperature may be maintained at any suitable temperature and/or within a predetermined temperature range. For example, if asphalt cools below the high temperatures needed to fluidize asphalt may result in the valve becoming inoperable. As such, the heating system may be provided to maintain the asphalt immediately near the valve at a sufficiently high temperature to prevent the asphalt from cooling (albeit not freezing) to a temperature wherein the asphalt would become less fluid or even harden and cause the valve to stick or otherwise become inoperable.

it is noted that more than one valve heater 10 may be implemented. In the illustration shown in FIG. 1, for example, other valve heater(s) may be installed between the valve 1 and conduit section 3 and/or conduit section 4.

FIGS. 1A-1B are perspective views of an example valve heater 10. FIG. 2 is a side plan view of the example valve heater 10 shown in FIGS. 1A-1B. The valve heater 10 may include a housing 16 with a heater bore 18 formed through the housing 16. The heater bore 18 may be configured with a similar inner diameter as a conduit to be connected to the valve heater 10 (e.g., conduit section 2 shown in FIG. 1) and/or an opening to the valve 1 (see FIG. 1).

As noted above, the valve heater 10 may include a first flange 12 and a second flange 14. Each of the first and second flanges 12 and 14 further include a plurality of fastener through-bores (e.g., through-bores 20 a on flange 14 and through-bores 20 b on flange 12 are labeled in FIGS. 1A-1B). The through-bores or fastener ports are configured for receiving fasteners to couple the valve heater 10 between the valve 1 and the conduit 2 (or structure, such as another valve, tank, etc.).

In an example, the valve heater 10 is configured as a cylinder having an interior and an exterior defined between proximal and distal ends. The first flange 12 is provided to the cylinder proximal end, and the second flange 14 is provided to the cylinder distal end. While the cylinder and flanges may be configured to any of a variety of dimensions, in an example, the cylinder is 6″×″ and 0.1875″ thick, and the flanges are 4″ standard and ⅝″ thick. Additionally, a 4″ schedule 80 center or bore may be incorporated therein.

In an example, the valve heater 10 may include a rectangular section 22 for the heating chamber and heating element (see FIG. 3). While the rectangular section 22 may have any of a variety of dimensions, in an example, the length may be approximately 4 inches while the width is approximately 2 inches.

FIG. 3 is a cross-sectional view of the example valve heater shown taken along lines 3-3 in FIG. 1B. The housing 16 may include a heating chamber 24 formed therein (shown in its entirety in cross-hatch). The heating chamber 24 may retain a heating fluid that can be maintained at a predetermined temperature. For example, an electric heating element 26 may be disposed in thermal contact with the heating chamber 24 (e.g., inside the heating chamber, adjacent, or otherwise) to heat the heating fluid therein. Any suitable heating fluid may be provided in the heating chamber 24, and may vary by application, cost, and/or other design considerations.

In an example, the heating chamber 24 at least partially surrounds the bore 18 to maintain a predetermined temperature or temperature range of the fluid therein. The heating element 26 may be provided through the distal facet into thermal communication with the heating chamber 24 to increase the temperature of a heating fluid.

FIG. 4 illustrates a connection platform 30 on the example valve heater. The connection platform 30 connects with an electronics housing. A plug 32 (e.g., ⅜″ National Pipe Thread plug) may be provided in the connection platform 30 to enable filling and/or draining heating fluid in the heating chamber 24. In an example, the plug is provided on a 6″×6″ collar opposite from the heating element 26. Another opening 34 (e.g., a ⅜″ National Pipe Thread opening) may also be provided in the housing 30 for the heating element 26 to extend therethrough.

During operation, heat from the heating element 26 is transferred to the heating fluid in the heating chamber 24, which is in turn transferred to the heater bore 18. As such, the fluid (or other matter) within the heater bore 18 is maintained at a predetermined temperature to prevent freezing of the fluid (or other matter) immediately adjacent the valve 1.

FIG. 6 illustrates a control box for the example valve heater. The control box may include bottom portion 36 a and cover portion 36 b of an electronics housing. The electronics housing may be removably coupled with the connection platform 30 (e.g., on a distal facet of the connection 30) to selectively protect the heating element 26 and the other control electronics. While the electronics housing may be provided in any of a variety of dimensions, in one example, the cover portion 36 b of electronics housing measures approximately 3″×4″×2″.

in an example, a fastener is configured for coupling the lower portion 36 a of the electronics housing to the connection platform 30 by cooperating with a threaded bore formed in the distal facet. The threaded bore may include a 1″ National Pipe Thread bore facilitating fastening of the electronics housing with a threaded fastener such as a ⅜″ bolt.

Control electronics may be provided in electronics housing to control operation of the valve heater 10. In an example, a thermostat 28 may be provided in thermal contact with the heating chamber 14. The thermostat 28 can be provided to control operation of the heating element 26 (e.g., to maintain the predetermined temperature).

Other control electronics may also be provided. For example, a temperature-controlled circuit breaker may be provided through a distal surface into thermal communication with the heating chamber. The circuit breaker can be configured to arrest operation of the heating element 26 in response to detecting a threshold temperature of heating fluid within the heating chamber 24.

An electrical conduit port 38 may be formed in a cover 36 c of the electronics housing to harness an electrical conduit 40 to provide power to the control electronics and the heating element 26. A power switch 42 may also be provided (e.g., to turn the valve heater 10 on and off).

FIG. 6 shows another example valve heater 100. In this example, the valve heater 100 includes a heating chamber formed within the housing 116. The heating chamber may be solid and/or include a heating fluid. The heating chamber may also extend up to end plate 118, or is otherwise in thermal contact with end plate 118.

In this example, the valve heater 100 is provided with a spin collar 150 a to connect to a valve, such as valves found on a railroad tanker car. FIGS. 7A-B illustrate the example valve heater shown in FIG. 6 as the valve heater may be implemented on a railroad tanker car 200.

By connecting the valve heater 100 to valve 210 (e.g., tanker drain valve or other fixture) and operating the heating element (e.g., in bottom portion and cover portions 136 a and 136 b of connection 130) via electricity provided by cable 140, as already described above for the example valve heater 10, the valve 210 (and any fluid held behind the valve) is maintained at a predetermined temperature to prevent the valve 210 from freezing. The valve heater 100 can be removed, as illustrated in FIG. 7B, and a hose or other conduit 220 connected to the valve 210, e.g., to drain the tanker.

Before continuing, it should be noted that the examples described above are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein.

A method of heating a valve is also disclosed. In an example, the method includes providing a housing having an interior and an exterior defined between proximal and distal open ends. The method also includes providing a first flange to mount the housing to a conduit. The method also includes providing a second flange to mount the housing to the valve. The method also includes providing a heating element to maintain a predetermined temperature or temperature range within the interior of the housing. During operation, a fluid (or gas or other component such as asphalt) in the housing adjacent the valve is heated to prevent freezing of the valve.

In an example, the heater bore may also be heated to melt or thaw a frozen working fluid (or increase temperature of other matter such as to liquefy asphalt).

A method of manufacture of a valve heater is also disclosed, in an example, a cylinder is provided with an interior and an exterior defined between proximal and distal ends, a first flange 12 is mounted to the cylinder proximal end and a second flange 14 is mounted to the cylinder distal end. Mounting may be by welding. A plurality of bores are formed through the first and second flanges 12 and 14.

A housing, which may be formed as a rectangular base cylinder truncated along an oblique plane, is coupled to the cylinder exterior so as to form a heating fluid chamber 24. Coupling of the housing to the cylinder exterior may include inserting a proximal edge of the housing into a passage formed in the cylinder exterior.

To provide a distal facet, an end plate is coupled to the housing remote from the cylinder exterior, for example, by welding. A heating element and control electronics (e.g., a temperature controlled circuit breaker) are inserted into the housing, through the end plane, and into thermal communication with the heating fluid chamber.

The cylinder may be installed or inserted between a valve and a fluid conduit and coupled thereto by inserting a plurality of fasteners through the bores formed in the first and second flanges. To facilitate immersion of the heating element, the housing, element block and control block may be mounted in a downward position underneath the cylinder to help ensure the heating element remains immersed in the heating fluid.

A heating fluid may be provided to the housing. With a heating fluid provided, the heating fluid is heated with the heating element. The heating element may be deactivated, e.g., with the temperature controlled circuit breaker upon detecting a threshold temperature of the heating fluid.

The operations shown and described herein are provided to illustrate example implementations. It is noted that the operations are not limited to the ordering shown. Still other operations may also be implemented.

It is noted that the examples shown and described are provided for purposes of illustration and are not intended to be limiting. Still other examples are also contemplated. 

1. A heater, comprising: a heating chamber; a heating element disposed in thermal contact with the heating chamber; a connection to attach the heating chamber to a valve.
 2. The heater of claim 1, wherein the heating chamber is configured to retain a heating fluid.
 3. The heater of claim 1, wherein the heating element is an electric heating element.
 4. The heater of claim 1, further comprising a bore formed through a housing.
 5. The heater of claim 4, wherein the heating chamber at least partially surrounds the bore formed within the housing.
 6. The heater of claim 1, further comprising a thermostat in thermal contact with the heating chamber, the thermostat to control operation of the heating element.
 7. The heater of claim 6, further comprising a temperature-controlled circuit breaker provided through a distal surface into thermal communication with the heating chamber, wherein the circuit breaker is configured to arrest operation of the heating element in response to detecting a threshold temperature of heating fluid within the heating chamber.
 8. The heater of claim 1, wherein the connection includes a spin collar.
 9. The heater of claim 1, wherein the connection is configured to attach to a railroad tanker car.
 10. The heater of claim 1, wherein the connection includes a first flange and a second flange.
 11. The heater as set forth in claim 9, wherein the first and second flanges further comprise a plurality of fastener through-bores, the first flange configured to mount to a conduit, and the second flange configured to mount to a valve.
 12. The heater of claim 1, further comprising an electronics cover removably coupled with the housing to seal and protect the heating element and other electronics from a surrounding environment.
 13. A heating system for installation adjacent a valve to control temperature near the valve, comprising: a housing having a heating chamber formed therein, the heating chamber configured to retain a heating fluid; an electric heating element disposed in thermal contact with the heating chamber; a connection to attach the heating chamber to the valve.
 14. The heating system of claim 13, further comprising a bore formed through a housing, the bore providing passage for a fluid through the housing, and wherein the heating chamber at least partially surrounds the bore to maintain a predetermined temperature or temperature range of the fluid adjacent the valve.
 15. The heating system of claim 13, further comprising a thermostat in thermal contact with the heating chamber, the thermostat to control operation of the heating element.
 16. The heating system of claim 15, further comprising a temperature-controlled circuit breaker provided through a distal surface into thermal communication with the heating chamber, wherein the circuit breaker is configured to arrest operation of the heating element in response to detecting a threshold temperature of heating fluid within the heating chamber.
 17. The heating system of claim 13, further comprising a first flange and a second flange, wherein the first and second flanges further comprise a plurality of fastener through-bores, the first flange configured to mount to a conduit, and the second flange configured to mount to a valve.
 18. The heating system of claim 13, wherein the connection includes a spin collar to attach to a railroad tanker car.
 19. A method of heating a valve, comprising: providing a housing having an interior and an exterior defined between proximal and distal open ends; providing a first flange to mount the housing to a conduit; providing a second flange to mount the housing to the valve; providing a heating element to maintain a predetermined temperature or temperature range within the interior of the housing.
 20. The method of claim 19, further comprising heating a fluid in the housing adjacent the valve to prevent freezing of the valve. 